CN104844228B - Pour mass, elements for castable compositions and their production method - Google Patents

Pour mass, elements for castable compositions and their production method Download PDF

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Publication number
CN104844228B
CN104844228B CN201510146312.8A CN201510146312A CN104844228B CN 104844228 B CN104844228 B CN 104844228B CN 201510146312 A CN201510146312 A CN 201510146312A CN 104844228 B CN104844228 B CN 104844228B
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elements
particle size
castable compositions
castable
size fraction
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CN104844228A (en
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J·泰肯
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Vesuvius USA Corp
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Vesuvius Crucible Co
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Abstract

The elements for castable compositions of low water content produces the cast product of the porosity with the rupture modulus improved, the crushing strength of raising and reduction.The composition closes particle size fraction to produce these performances using the composition particle with specific distribution and specific interval in particle size distribution.Said composition is suitable for application to refractory.

Description

Pour mass, elements for castable compositions and their production method
The application be the applying date for August in 2008 28 days, it is entitled " pour mass, elements for castable compositions and they The divisional application of the Chinese invention patent application 200880104605.8 of production method ".
Invention field
The present invention relates to the elements for castable compositions of the matrix content with reduction, such as golden to receiving liquid is intended to The lined fire proofing composition of container and interior melter walls of category, glass etc..It further relates to what is produced by these compositions and method Pour mass.
Background of invention
The method of known many linings being used on production metallurgy container inner wall.Therefore, according to it is known in the art so Method, in the method, inorganic particle (optionally containing fiber) and organic and/or inorganic bond are included by be capable of set The aqueous pasty mixture of agent is applied to metallurgy with spatula, pneumatic tube conveyor or other casting devices by molding, making firm by ramming or cast Container is for example cast the inside of tundish.Granulate mixture during liquid metal contacts with sintering, which ensure that the adherence of lining.
According to prior art, it is also known that such method, according to this method, at least two layers different composition is applied to The inside of metallurgical tank, applied each via the aqueous pasty mixture for being capable of set for casting the above-mentioned type.
The mobility (application for promoting them) of these aqueous pasty mixtures is proportional to the amount of existing wet water.Must The wet water for being used for forming aqueous mixture must be removed by drying, this is related to immobilization (immobilization) time and energy Amount consumption, both of which are very important.
Method as it is known that presence, according to this method, template is placed in inside metallurgical tank, will by refractory particle and By can the material that forms of thermoset adhesive cast and arrived template and container inner wall by pneumatic action, then apply and heat and same When maintain template in the original location so that adhesive set, finally removes template.Mould material includes the inorganic chemical containing the crystallization water Thing.The crystallization water is the water combined with crystal chemistry, is required for maintaining crystalline state performance, but can be removed by fully heating Go.
It is also known that can be by the vibrating casting of water-bearing concreae, or by with the concrete from flowable consistency Cast without friction, refractory is manufactured by the cast of refractory concrete.In two methods, all concrete materials need uniformly mixed Close and soak.Generally, matrix and roughage are compounded together.Then water is added to form preferable shape to produce mobility and trigger The reaction of the final products of shape.Therefore, the major part of material is particulate matrix material.The material has high surface area, and this makes Itself is prone to corrode in for example most of refractory applications of unfavorable conditions.The water of larger proportion improves the stream of mixture Dynamic property, but promote the formation of formed product mesopore.High mixing water content means to grow very much in pourable thing The desiccation time and difference mechanical strength.The water of small percentage suppresses hole and formed, but produces and be easy to ftracture, crush and dissipate The product component split.In egregious cases, the part of adhesion can not be formed using the preparaton of small scale water.
To improve thermal shock resistance, fibrous material is being used in vibrating casting material and from fluent material.Fibrous material Use improve the needs to high-caliber mixing water and make cast increasingly difficult.Due to they high density and to anti-slag Property beneficial very thick material can only be used to a certain extent because mixed with very high roughage content The cast for coagulating soil is extremely difficult.
Also the article of the relatively fine particle introduced in slurry form is produced containing coarse granule and is mixed with using osmosis.Example Such as, mould can be filled with the drying coarse granule can with about 1-60mm sizes to form the dried object of shaping.Then with by gluing Dried object is shaped described in the slurry penetration that the thin packing material that mixture, water and particle size distribution are 0.0001-3mm is formed.Root Infiltration according to this method is time-consuming process.The difficulty of thick parts is produced by this method to be increased with component thickness, unless making With larger aggregate.
The purpose of the present invention is the shortcomings that overcoming known compositions, and the amount for producing wherein mixing water be minimized, The density that the porosity that the amount of matrix material was minimized, shaped dried object was minimized, shaped dried object is improved Product, and production with improve rupture modulus and crushing strength value product.
Summary of the invention
It has been found that some composition characteristics produce castable material either individually or in combination, the material is in the group with prior art When compound is compared, the density improved and the porosity reduced can be prepared and shown with the water of decrement.These are special Sign includes：
1) most thick fire resisting particle size fraction (grain fraction) accounts for 50 weight % or bigger of dry composition；The particle size fraction By smallest particles diameter and the largest particles diameter ratio it is at least with smaller particle size levelOr at least 2 interval (gap) separates Open.For example, most thick fire resisting particle size fraction can be made up of particle of the diameter more than 500,800 or 1000 microns, and it can be tool There is the closing particle size fraction of such as 1000,2000 or 4000 microns of maximum particle size.
2) said composition contains at least four particle size fraction, wherein being at least by particle diameter ratioInterval or by particle Diameter than be at least 2 the residuals weight percentage (particles in the particle size fraction that have of the neighbouring particle size fraction in interval separate 3 Percetage by weight on all particles in the particle size fraction plus the weight of all smaller particles) relative to each close to larger Particle size particle size fraction and by successively decrease particle size order be smaller value, higher value and smaller value.It is this configuration (compared with Greatly, smaller, larger and less particle size fraction) it is named as " alternately residuals weight percentage " composition.
3) said composition contains at least four particle size fraction, wherein being at least by particle diameter ratioInterval or by particle Diameter than be at least 2 the residuals weight percentage (particles in the particle size fraction that have of the neighbouring particle size fraction in interval separate 3 Percetage by weight relative to all particles in the particle size fraction plus the weight of all smaller particles) on each immediately larger Particle size particle size fraction and by successively decrease particle size order be higher value, smaller value and higher value.It is this configuration (compared with Small, larger, smaller and larger particle size fraction) it is named as " alternately residuals weight percentage " composition.
4) said composition contains at least two or at least three particle size fraction, and the particle size fraction is at least by particle diameter ratio Or particle diameter is made up of particle of the diameter less than 100 microns completely than being that at least 2 interval separates.
5) said composition contains at least four particle size fraction, and the particle size fraction is at least by particle diameter ratioOr particle is straight Footpath is than being that at least 2 interval separates, and wherein residuals weight percentage is at least 40%.
6) said composition contains at least five particle size fraction, and the particle size fraction is at least by particle diameter ratioOr particle is straight Footpath is than being that at least 2 interval separates.
7) at least two in the interval is each less than 10 mass % or less than 5 mass % containing dry composition quality.
The composition for including these one or more features is prepared for, wherein utilizing 6.0 weight %, 5.0 weight %, 4.0 Weight %, 3.0 weight %, 2.5 weight % and 2.0 weight % water percetage by weight, are improved relative to prior art MOR (rupture modulus), CCS (crushing strength) value of the bulk density of raising, the porosity reduced and raising.
Using the composition of the present invention, measured at 230 °F 1000 or bigger, 2000 or bigger, 3000 or more can be obtained Greatly, 3500 or bigger and 12000 or bigger MOR values (with a pound/square inch measurement), and measured at 1500 °F 500 or It is bigger, 1000 or bigger, 2000 or bigger, 3000 or bigger and 3500 or bigger MOR values.
Using the composition of the present invention, measured at 230 °F 190 or bigger, 195 or bigger, 200 or bigger can be obtained Bulk density value (is measured) with pound/cubic feet, and measured at 1500 °F 185 or bigger, 190 or bigger, 195 or more Big or 200 or bigger bulk density value.
Using the present invention composition, can obtain measured under 230 °F 15 or smaller, 10 or smaller, 5 or smaller, 4 or It is smaller or 3 or smaller porosity (with volume % measure), and measured under 1500 °F 18 or smaller, 15 or smaller, 10 or smaller, 5 or smaller, 4 or smaller or 3 or smaller porosity.
Using the composition of the present invention, measured at 230 °F 3000 or bigger, 5000 or bigger, 8000 or more can be obtained Greatly, 10,000 or bigger and 12000 or bigger CCS values (being measured with pound/square inch), and measured at 1500 °F 3000 or bigger, 5000 or bigger, 8000 or bigger, 10,000 or bigger and 12,000 or bigger CCS values.
Brief description
Fig. 1 is the composition on prior art and the present invention, and composition particle size fraction percetage by weight is relative to by logarithm The coordinate diagram that the particle size that scale represents is drawn；
Fig. 2 is the composition on the present invention, and composition particle size fraction percetage by weight by logarithmic scale relative to being represented The coordinate diagram that particle size is drawn；
Fig. 3 is the composition on the present invention, and composition particle size fraction percentage by volume by logarithmic scale relative to being represented The coordinate diagram that particle size is drawn；
Fig. 4 is the composition on the present invention, and composition particle size fraction percentage by volume by logarithmic scale relative to being represented The coordinate diagram that particle size is drawn；
Fig. 5 is the composition on prior art, and composition particle size fraction percetage by weight represents relative to by logarithmic scale Particle size draw coordinate diagram；
Fig. 6 is the composition on prior art, and composition particle size fraction percetage by weight represents relative to by logarithmic scale Particle size draw coordinate diagram；With
Fig. 7 is the composition on the present invention, and composition particle size fraction percetage by weight is relative to the particle by logarithmic scale The coordinate diagram that size is drawn.
Detailed description of the invention
It was found that the amount that the presence of some composition characteristics or combine generates wherein mixing water is minimized, matrix material The porosity that amount was minimized, shaped stem body is minimized, shapes the refractory product that the density of stem body is improved, and The product of rupture modulus and crushing strength value with raising.
Coarse aggregate useful in the embodiment of this invention can contain fused alumina or sintered alumina (plate-like aluminum oxide), complete The magnesia of the mullite of whole alumina balls, consolidation bauxite, consolidation and sintering, consolidation and sintering, consolidation and the oxidation of sintering The zirconium oxide of magnesium aluminate spinel, consolidation and sintering, fire resisting bauxite, fire resisting kyanite, fire resisting andalusite, fire resisting sillimanite, carbon SiClx, or combinations thereof.
Coarse aggregate useful in the embodiment of this invention can have any shape.They can be spherical, block, rectangle or even Threadiness.In addition, they can be used alone or in combination.
Adhesive for matrix can contain aluminous cement, α combination cement, Portland cement, monoaluminum phosphate (MAP), clay, activated alumina (such as AA 101), the aluminum oxide that can be hydrated, and combinations thereof.In some embodiments In, cement is not contained according to the matrix material of the present invention.
Other raw materials for matrix can include activated alumina, calcined alumina, plate-like aluminum oxide, consolidation oxidation Aluminium, mullite, carbon (graphite or carbon black), carborundum, zirconium dioxide, magnesia, aluminosilicate (such as kyanite, andalusite or Sillimanite), SILICA FUME, bauxite, chromium oxide and combinations thereof.A diameter of 0.01-10 microns of the preparaton part ( Referred to as fines) activated alumina and silicon ash (fume silica) can be contained.
Matrix can also contain dispersant, plasticizer, defoamer or foaming agent and outgassing components.These reagents are in ability It is known in domain.
The method of the present invention produces pourable mixture with the fine grained of minimum volume.Generally, pourable thing institute is produced The fine grain amount needed depends on the size of highest sized particles.Highest granularity typically needs minimum for the compound of 3 mesh 33 volume % -100 mesh particles form the pourable mixture of feature.It can be produced with 30 volume % according to the present invention or more Small -100 mesh particles, 29 volume % or smaller -100 mesh particles, 26 volume % or smaller -100 mesh particles, 25 volume % Or smaller -100 mesh particles, 22 volume % or smaller -100 mesh particles or the volume % of 24 volume % (including the value) -18 The useful pourable mixture of -100 mesh particles of (including the value).
Pourable mixture with 3 mesh highest granularities typically needs 48 volume % of minimum -16 mesh particles to be formed The pourable mixture of feature.It can be produced with 47 volume % or smaller -16 mesh particles, 45 volume % or more according to the present invention The useful pourable mixture of -16 small mesh particles or 43 volume % or smaller -16 mesh particles.
Pourable mixture with 3 mesh highest granularities typically needs 58 volume % of minimum -6 mesh particles to form work( Can the pourable mixture of property.It can be produced with 55 volume % or smaller -6 mesh particles, 47 volume % or smaller according to the present invention - 6 mesh particles, 42 volume % or smaller -6 mesh particles or 36 volume % or smaller -6 mesh particles it is useful pourable mixed Compound.Unrelated with highest granularity, the pourable mixture of prior art needs the fine aggregate of minimum volume.These minimum volume classes It is similar to just have the value given by the compound of 3 mesh highest granularities.Mesh value is represented by Tyler values herein.
In addition, it is -6 mesh particles, -14 mesh particles, -16 mesh shown by the pourable mixture of 3 purposes with regard to highest granularity The maximum volume percent value of grain, -28 mesh and -100 mesh particles can be additionally used in production and be more than 3 purposes most according to having for the present invention The pourable mixture of high granularity or aggregate.For example, -3/8 " aggregate, 1/2 " x1/4 " aggregates, -1/2 " aggregate, -3/4 " aggregate With -1 " mixture of the aggregate of aggregate, these aggregates and highest granularity in the range of -3 mesh to 12 " (including end value) can be used for Production is according to elements for castable compositions of the invention.
The pour mass of the method production of the present invention has the density that previously just used composition is unreachable to.It is if existing The alumina base casting for having technology includes chromium oxide, and then they can be with the close of up to 202 pounds/cubic feet in raw state Degree.Raw state material contains free water；This water can be removed by being heated to 230 °F.Can it is produced according to the invention go out There is 204 pounds/cubic feet or bigger or 210 pounds/cubic feet or the cast of the alumina base of bigger density in raw state Thing.
They can have up to after drying to 230 °F if the alumina base casting of prior art includes chromium oxide The density of 199 pounds/cubic feet, or can have 196 pounds/cubic feet in raw state if they only include aluminum oxide Density.According to the present invention can produce dry to have after 230 °F 200 pounds/cubic feet or it is bigger, 202 pounds/cubic feet per Chi or the bigger or alumina base casting of 207 pounds/cubic feet or bigger density.
The pour mass of the method production of the present invention has the density being previously unreachable to (relative to solid density).It is theoretical Density refers to for the accessible most high-density of material (that is, with having being free of of distinguishing of accumulation powder in gap between particle The solid sample in gap).Aluminum oxide has the solid density of 247.53 pounds/cubic feet.Prior art, which can produce, to be had (196.0/247.53) × 100% or 79.2% solid density or (199.0/247.53) × 100% or 80.3% theory are close The material of degree.Material produced by the invention has (200.0/247.53) × 100% or 80.7% solid density or bigger, Or equal or exceed 83.6% density of solid density.
The method of the present invention can produce the castable material with the amount of liquid reduced.The castable material of prior art Typically containing at least 3.7 weight % liquid.It can be produced with 3.3 weight % liquid or less, 3.0 weights according to the present invention Measure % liquid or less, 2.0 weight % liquid or 1.7 weight % liquid or less castable material.Prior art can Mould material is typically containing at least 10.9 volume % liquid.It can be produced with 9.1 volume % liquid according to the present invention or more Less or 7.8 volume % liquid or less castable material.These percentages are total relative to aggregate, matrix, fines and water Weight or cumulative volume are indicated.
The method of the present invention can produce the pour mass with the porosity reduced.Poured by what existing placingJi Shu produced Injection body is in the porosity level for being heated to have not less than 13% after 1500 °F.According to the present invention can produce with less than 13%, Less than 12%, less than 11%, less than 10%, less than 9%, less than 8%, less than 7%, less than 6%, less than 5%, less than 4% or The pour mass of porosity level less than 3%.
In the method according to the invention, pourable material, integrated cast structure body and cast product such as columnar structures can use The elements for castable compositions of the present invention is built.It the described method comprises the following steps：(a) mould with cavity, the sky are provided Chamber corresponds to structure or pours into a mould the size and dimension of product, and (b) fills cavity with the elements for castable compositions of the present invention, and (c) appoints The elements for castable compositions of the present invention is compacted and/or vibrated by selection of land, and (d) solidifies the elements for castable compositions can be poured with being formed Material, integrated cast structure body or cast product are noted, and (e) separates mould with pourable material, integrated cast structure body or cast product.This hair Bright composition can be additionally used in compression molding process, wherein the composition of moistening is placed in a mold, and carry out machine to it Tool or fluid power compacting or other compressions processing, with the part of shape needed for formation or cast product.
Elements for castable compositions of the invention can be heated to obtain the good green strength for being suitable to be stripped.110 can be heated to DEG C make active oxidation reactive aluminum.Alternately or in addition, cement can be used for fine grained material to provide green strength.
The reality shown in Table I is poured into a mould using the plate-like aluminum oxide and the cement of Secar 71 of illustrated dimension as adhesive Example.Secar 71 is the hydraulic binder with about 70% alumina content.ULM2 is that have four in particle diameter distribution The composition of the invention at individual peak；Two of which peak corresponds to the particle with 250 microns or smaller diameter.ULM3 and ULM3B For two kinds of compositions of the present invention, these compositions have 3 particles corresponding to a diameter of 1000 microns or smaller of particle Diameter distribution of peaks.PA1 and PA2 is the composition of prior art.ULM1 is the composition of the present invention, and said composition is by composition PA2 is by changing the distribution of particles in sub- 100 microns of (or -60 mesh) scopes and being spaced by introducing in the above range Arrive.
" carrying capacity (loading) " value in Table I and II represents residuals weight percentage, being defined as in given particle size fraction Percetage by weight of the grain relative to all particles in the particle size fraction plus the weight of all smaller particles.For example, contain in ULM2 The particle size fraction for having the largest particles includes the aluminum oxide and silica of 53 weight % in composition.Particle size fraction containing the second bulky grain The 50 weight % comprising remainder particulate.Particle size fraction containing the third-largest particle includes 35 weight % of remainder particulate.Contain the 4th The particle size fraction of bulky grain (it is also smallest particles) includes 100 weight % of remainder particulate.
Composition ULM1, ULM3 and ULM3B include 4 or more the particle size fractions with alternately residuals weight configuration.PA1 Lack such configuration with PA2.ULM2 also lacks the alternating residuals weight configuration of 4 particle size fractions, but have really with it is a diameter of 2 corresponding peaks of 250 microns or smaller of particle.
Composition PA1 and PA2 need shown water (6.34 weight % and 5.25 weight % respectively) to produce cast production Product.
A3000FL is that have the d50 of about 2.5-3 microns and by BET (Brunauer-Emmet t-Tel ler) method The specific surface area of measurement is typically ultra-fine, the bimodal activity aluminum oxide of 1.3-2 meters squared per grams.A152SG is with intermediate value grain Footpath is the ultra-fine alumina of 1.2 microns of unimodal particle size distribution.RG 4000 be have 0.5-0.8 microns d50 it is unimodal Activated alumina.Dispex N100 are sodium polyacrylate disperants.
The present invention ultralow matrix composition ULM1, ULM2, ULM3 and ULM3B with prior art compositions PA1 and PA2 Compared to when show MOR, bulk density and CCS raising and the reduction of porosity.These compositions are shown in tablei Component and performance.
Table I：The contrast of component and physical property
The present composition ULM-FG, ULM-PG and ULM-671 can be produced when compared with prior art compositions PA2 The pourable material of water percentage with reduction.Various compositions are shown in Table II；Show in table iii and add various ratios The performance comparision for the pourable material that the water of example is produced.
Table II：The contrast of composition
All samples are carried out with the dry-mixing of 30 seconds, the wet mixing of 4.5 minutes is closed, the high vibration of 4 minutes and 1 minute low are shaken It is dynamic.KBD values are with the bulk density of pound/cubic feet measurement.KPOR values are the porosity values measured by percentage by volume.KBD Value and KPOR values are 1500 °F of values.Mark DNB is provided for uncombined composition.For unconsolidated composition to bid Note DNC.
The ultralow matrix composition of the invention of water at high proportion is for example wherein added for comparative purposes in some compositions In, observe the separation of grain graininess level.The value that " whole " is designated as in table is to represent whole cross sections from top to bottom of sample Part measurement result.The value that " bottom " is designated as in table is the measurement result for the sample part for being closer to vibration source.In Table III The percentage of water is percetage by weight.
Table III：The performance for the part poured into a mould by prior art and the present composition
Pair of particle size distributions 12 of the Fig. 1 containing with good grounds prior art and the particle size distribution 14 according to the present invention Than.The composition ULM2 that particle size distribution 14 corresponds in Table I.In the figure, in dry composition particle percetage by weight Function as particle size (in microns, being represented by logarithmic scale) is drawn.
Criterion SR 92CF are to can be used for fine particle materials of the production according to the pour mass of prior art.It contains Thin activated alumina adhesive.In Table IV and V, by its size distribution (in terms of mesh) and its chemical composition and according to the present invention Fine particle materials (showing particle size interval) contrasted.
Table IV：The present invention and the contrast of the particle size particle size fraction of prior art
Criterion SR 92CF, % The material of the present invention, %
+3M 0.0 41.7
3X4M 0.3 5.5
4X6M 15.8 9.9
6X8M 7.3 0.6
8X12M 5.6 0.0
12X16M 4.7 0.2
16X20M 8.4 3.2
20X30M 6.3 2.7
30X40M 3.5 1.5
40X50M 7.6 4.5
50X70M 3.2 1.9
70X100M 2.6 1.6
-100M 34.6 26.7
Table V：The contrast of the present invention and the chemical composition of prior art
Fig. 2 depicts the particle size distribution according to the present invention, wherein 6 particle size fractions have alternate residuals weight percentage Number configuration, alternately until reaching last particle size fraction between 33% and 48%.Although before last particle size fraction is reached these The percetage by weight of particle size fraction reduces with the reduction of particle size, but 6 maximum particle size fractions show alternate residue Percetage by weight configures.Particle of first particle size fraction 21 containing 33 weight %；67 weight % particle residue is got off.Second granularity Particle of the level 22 containing (67*0.48) or 32.2 weight %.Therefore most preceding 2 particle size fractions contain 65.2 weight %；34.8 weights Amount % residues are got off.Particle of 3rd particle size fraction 23 containing (34.8*0.33) or 11.5 weight %.Therefore most preceding 3 particle size fractions Contain 76.7 weight %；23.3 weight % residues are got off.Of 4th particle size fraction 24 containing (23.3*0.48) or 11.2 weight % Grain.Therefore most preceding 4 particle size fractions contain 87.9 weight %；12.1 weight % residues are got off.5th particle size fraction 25 contains (12.1* 0.33) or 4.0 weight % particle.Therefore most preceding 5 particle size fractions contain 91.9 weight %；8.1 weight % residues are got off.6th Particle size fraction 26 contains (8.1*0.48) or 3.9 weight %.Therefore most preceding 6 particle size fractions contain 95.8 weight %；4.2 weight % are remained Remainder is come.7th particle size fraction 27 is remaining unique particle size fraction, therefore it contains 4.2 weight % particle, or 100 weight % Remainder particulate.
Fig. 3 depicts present composition ULM3 particle size distribution.In the figure, in dry composition particle volume Percentage is drawn as the function of the particle size (in microns) represented by logarithmic scale.Show the first particle size fraction 31st, the second particle size fraction 32, the 3rd particle size fraction 33, the 4th particle size fraction 34, the 5th particle size fraction 35 and the 6th particle size fraction 36.First granularity Level 31 has 48% residual volume percentage.Residual volume percentage is 32% for the second particle size fraction 32, for the 3rd It is 42% to spend level 33, is 48% for the 4th particle size fraction 34, and is 44% for the 5th particle size fraction 35.Residual volume percentage Be the particle in indicated scope volume relative in all scopes particle (wherein particle have compared with indicated scope Identical or less diameter) cumulative volume percentage by volume.6th particle size fraction 36 (particle size fraction containing smallest particles) has 100% residual volume percentage.
Fig. 4 depicts present composition ULM3B particle size distribution.In the figure, in dry composition particle body Product percentage is drawn as the function of the particle size (in microns) represented by logarithmic scale.Show the first particle size fraction 41st, the second particle size fraction 42, the 3rd particle size fraction 43, the 4th particle size fraction 44, the 5th particle size fraction 45 and the 6th particle size fraction 46.First granularity Level 41 has 48% residual volume percentage.Residual volume percentage is 30% for the second particle size fraction 42, for the 3rd It is 41% to spend level 43, is 41% for the 4th particle size fraction 44, and is 49% for the 5th particle size fraction 45.Residual volume percentage Be the particle in indicated scope volume relative in all scopes particle (wherein particle have compared with indicated scope Identical or less diameter) cumulative volume percentage by volume.6th particle size fraction 46 (particle size fraction containing smallest particles) has 100% residual volume percentage.
The mass percent that Fig. 5 includes the particle size fraction that PA1 is prior art compositions is straight relative to particle in microns The coordinate diagram in footpath.The coordinate diagram describes the first particle size fraction 51, the second particle size fraction 52 and the 3rd particle size fraction 53.3rd particle size fraction 53 Containing all material in composition with 100 microns or smaller diameter, and show unimodal.First particle size fraction 51 is containing surplus The 45% of remaining weight, the second particle size fraction 52 containing residuals weight 46%, and the 3rd particle size fraction 53 contains residuals weight 100%.
The mass percent that Fig. 6 includes the particle size fraction that PA2 is prior art compositions is straight relative to particle in microns The coordinate diagram in footpath.The coordinate diagram describes the first particle size fraction 61, the second particle size fraction 62, the 3rd particle size fraction 63 and the 4th particle size fraction 64.4th particle size fraction 64 is shown unimodal containing all material in composition with 100 microns or smaller diameter.The One particle size fraction 61 containing residuals weight 40%, the second particle size fraction 62 containing residuals weight 33%, the 3rd particle size fraction 63 contains The 38% of residuals weight, and the 4th particle size fraction 64 containing residuals weight 100%.
Fig. 7 includes the mass percent for the particle size fraction that ULM1 is the present composition relative to particle diameter in microns Coordinate diagram.The coordinate diagram describes the first particle size fraction 72, the second particle size fraction 72, the 3rd particle size fraction 73, the 4th particle size fraction 74, Five particle size fractions 75 and the 6th particle size fraction 76.Particle size fraction 71,72 and 73 contains particle size fraction identical weight hundred similar with PA2 Fraction.However, the micron fraction of Asia 100 of PA2 distribution of particles shows unimodal, and the ULM1 micron fraction of Asia 100 shows 3 Particle size fraction, i.e. particle size fraction 74,75 and 76.
The present invention includes：
1. elements for castable compositions, when with 2.8 weight % or the cast of smaller water content, caused by the elements for castable compositions Porosity with equal to or less than 15 volume % when cast product measures under 230 °F.
2. elements for castable compositions, when with 2.8 weight % or the cast of smaller water content, caused by the elements for castable compositions Rupture modulus with equal to or more than 1000 pounds/square inch when cast product measures under 230 °F.
3. elements for castable compositions, when with 2.8 weight % or the cast of smaller water content, caused by the elements for castable compositions Crushing strength with equal to or more than 3000 pounds/square inch when cast product measures under 230 °F.
4. elements for castable compositions according to claim 1, it is equal to wherein the cast product has when being measured under 230 °F Or the porosity less than 10 volume %.
5. elements for castable compositions according to claim 1, it is equal to wherein the cast product has when being measured under 230 °F Or the porosity less than 9 volume %.
6. elements for castable compositions according to claim 1, it is equal to wherein the cast product has when being measured under 230 °F Or the porosity less than 8 volume %.
7. elements for castable compositions according to claim 1, it is equal to wherein the cast product has when being measured under 230 °F Or the porosity less than 7 volume %.
8. elements for castable compositions according to claim 1, it is equal to wherein the cast product has when being measured under 230 °F Or the porosity less than 6 volume %.
9. elements for castable compositions according to claim 1, it is equal to wherein the cast product has when being measured under 230 °F Or the porosity less than 5 volume %.
10. elements for castable compositions according to claim 1, wherein when the cast product measure under 230 °F with etc. In or less than 4 volume % porosity.
11. elements for castable compositions according to claim 1, wherein when the cast product measure under 230 °F with etc. In or less than 3 volume % porosity.
12. according to the elements for castable compositions of any one of claim 1,4,5,6,7,8,9,10 and 11, wherein the hole Gap rate is obtained by being measured under 1500 °F.
13. elements for castable compositions according to claim 2, wherein when the cast product measure under 230 °F with etc. In or more than 2000 pounds/square inch of rupture modulus.
14. elements for castable compositions according to claim 2, wherein when the cast product measure under 230 °F with etc. In or more than 3000 pounds/square inch of rupture modulus.
15. elements for castable compositions according to claim 2, wherein when the cast product measure under 230 °F with etc. In or more than 4000 pounds/square inch of rupture modulus.
16. according to the elements for castable compositions of any one of claim 2,13,14 and 15, wherein the rupture modulus value is Obtained by being measured under 1500 °F.
17. elements for castable compositions according to claim 3, wherein the cast product has when being measured under 230 °F 5000 pounds/square inch of crushing strength.
18. elements for castable compositions according to claim 3, wherein the cast product has when being measured under 230 °F 8000 pounds/square inch of crushing strength.
19. elements for castable compositions according to claim 3, wherein the cast product has 10 when being measured under 230 °F, 000 pound/square inch of crushing strength.
20. elements for castable compositions according to claim 3, wherein the cast product has 12 when being measured under 230 °F, 000 pound/square inch of crushing strength.
21. according to the elements for castable compositions of any one of claim 3,17,18,19 and 20, wherein the cold pressing is broken strong Degree is obtained by being measured under 1500 °F.
22. according to any one of claim 1-21 elements for castable compositions, it is characterised in that most thick fire resisting particle size fraction At least 50% weight of dry composition is accounted for, and wherein most thick fire resisting particle size fraction passes through the largest particles diameter with smaller particle size level It is at least with smallest particles diameter ratioInterval separate.
23. according to any one of claim 1-21 elements for castable compositions, wherein the composition contains at least four grain Level is spent, wherein 3 neighbouring particle size fractions are at least by the ratio between particle diameterInterval separate, and this 3 neighbouring Particle size fraction has following residuals weight percentage, and the residuals weight percentage is on each close to larger particle size granularity Level and by successively decrease particle size order be smaller value, higher value and smaller value.
24. according to any one of claim 1-21 elements for castable compositions, wherein the composition contains at least four grain Level is spent, wherein 3 neighbouring particle size fractions are at least by the ratio between particle diameterInterval separate, and this 3 neighbouring Particle size fraction has following residuals weight percentage, and the residuals weight percentage is on each close to larger particle size granularity Level and by successively decrease particle size order be higher value, smaller value and higher value.
25. according to any one of claim 1-21 elements for castable compositions, wherein the composition contains at least two quilt The ratio between particle diameter is at leastThe particle size fraction that separates of interval, and at least two particle size fraction is less than by diameter completely 100 microns of particle is formed.
26. according to any one of claim 1-21 elements for castable compositions, wherein the composition contains at least three quilt The ratio between particle diameter is at leastThe particle size fraction that separates of interval, and at least three particle size fraction is less than by diameter completely 100 microns of particle is formed.
27. according to any one of claim 1-21 elements for castable compositions, wherein the composition contains at least four quilt The ratio between particle diameter is at leastThe particle size fraction that separates of interval, and the residue at least four particle size fraction in each Percetage by weight is at least 40%.
28. according to any one of claim 1-21 elements for castable compositions, wherein said composition contains at least five quilt Grain diameter ratio is at leastThe particle size fraction that separates of interval.
29. according to any one of claim 23-28 elements for castable compositions, wherein at least two in the interval is each Dry composition quality containing less than 10 mass %.
30. according to any one of claim 23-28 elements for castable compositions, wherein at least two in the interval is each It is less than 5 mass % containing dry composition quality.
31. according to the elements for castable compositions of any one of preceding claims, wherein the density that the cast product has For at least the 80.7% of solid density.
32. according to the elements for castable compositions of any one of preceding claims, wherein the density that the cast product has For at least the 83.6% of solid density.
33. according to the elements for castable compositions of any one of preceding claims, at least 95 weight % aluminum oxide is included.
34. according to the elements for castable compositions of claim 33, wherein the cast product has extremely when being measured under 230 °F The bulk density of few 190 pounds/cubic feet.
35. according to the elements for castable compositions of claim 33, wherein the cast product has extremely when being measured under 230 °F The bulk density of few 195 pounds/cubic feet.
36. according to the elements for castable compositions of claim 33, wherein the cast product has extremely when being measured under 230 °F The bulk density of few 200 pounds/cubic feet.
37. according to the elements for castable compositions of claim 33, wherein the cast product has extremely when being measured under 230 °F The bulk density of few 202 pounds/cubic feet.
38. according to the elements for castable compositions of claim 33, wherein the cast product has extremely when being measured under 230 °F The bulk density of few 207 pounds/cubic feet.
39. according to any one of claim 34-36 elements for castable compositions, wherein the bulk density is at 1500 °F Under measure.
40. by the cast product produced according to any one of claim 1-39 elements for castable compositions.
41. the method for producing cast product, the mould with cavity is provided comprising (a), the cavity corresponds to production The size and dimension of product, (b) with according to any one of claim 1-39 elements for castable compositions fill cavity, (c) optionally The elements for castable compositions of the present invention is compacted and/or vibrated, (d) solidifies the elements for castable compositions to form cast product, Mould with cast product is separated (e).
42. the method for producing cast product, the mould with cavity is provided comprising (a), the cavity corresponds to production The size and dimension of product, (b) fill cavity with according to any one of claim 1-39 elements for castable compositions, and (c) is to this hair Bright elements for castable compositions is compressed processing, and (d) solidifies the elements for castable compositions to form cast product, and (e) by mould Separated with cast product.
Described above is the content for being considered optimal mode of the present invention.It is apparent, however, to one skilled in the art that can be to this hair Spirit of the bright many changes for making described type without departing from the present invention.The scope of the present invention by appended claims art The extensive general sense of language limits.

Claims (39)

1. elements for castable compositions, when with 2.8 weight % or the cast of smaller water content, poured into a mould caused by the elements for castable compositions Porosity with equal to or less than 15 volume % when product measures under 230 °F, the elements for castable compositions include and account for dry combination At least 50 weight % most thick fire resisting particle size fraction of thing, wherein most thick fire resisting particle size fraction and smaller particle size level are straight by the largest particles Footpath and smallest particles diameter ratio are at leastInterval separate.
2. elements for castable compositions according to claim 1, wherein said composition contain at least two and are by the ratio between particle diameter At leastThe particle size fraction that separates of interval, and at least two particle size fraction is less than 100 microns of particle structure by diameter completely Into.
3. elements for castable compositions according to claim 1, it is equal to wherein the cast product has when being measured under 230 °F Or the porosity less than 4 volume %.
4. elements for castable compositions according to claim 1, it is equal to wherein the cast product has when being measured under 230 °F Or the porosity less than 3 volume %.
5. elements for castable compositions according to claim 1, have when it is measured under 1500 °F and be equal to or less than 15 bodies Product % porosity.
6. elements for castable compositions according to claim 1, it is equal to wherein the cast product has when being measured under 230 °F Or the porosity less than 10 volume %.
7. elements for castable compositions according to claim 1, it is equal to wherein the cast product has when being measured under 230 °F Or the porosity less than 8 volume %.
8. elements for castable compositions according to claim 1, wherein said composition contain at least five and are by the ratio between particle diameter At leastThe particle size fraction that separates of interval.
9. elements for castable compositions according to claim 1, wherein the density that the cast product has is solid density At least 80.7%.
10. elements for castable compositions according to claim 1, wherein the density that the cast product has is solid density At least 83.6%.
11. elements for castable compositions according to claim 1, include at least 95 weight % aluminum oxide.
12. elements for castable compositions according to claim 11, wherein the cast product has extremely when being measured under 230 °F The bulk density of few 190 pounds/cubic feet.
13. elements for castable compositions according to claim 11, wherein the cast product has extremely when being measured under 230 °F The bulk density of few 195 pounds/cubic feet.
14. elements for castable compositions according to claim 12, there are at least 190 pounds/cube when it is measured under 1500 °F The bulk density of foot.
15. elements for castable compositions according to claim 6, wherein at least two in the interval, which respectively contains, is less than 10 matter Measure % dry composition quality.
16. elements for castable compositions, when with 2.8 weight % or the cast of smaller water content, poured caused by the elements for castable compositions Rupture modulus with equal to or more than 1000 pounds/square inch when note product measures under 230 °F, the elements for castable compositions bag Containing at least 50 weight % most thick fire resisting particle size fraction for accounting for dry composition, wherein most thick fire resisting particle size fraction passes through with smaller particle size level The largest particles diameter and smallest particles diameter ratio are at leastInterval separate.
17. elements for castable compositions according to claim 16, wherein when the cast product measure under 230 °F with etc. In or more than 2000 pounds/square inch of rupture modulus.
18. elements for castable compositions according to claim 16, should when with 2.8 weight % or the cast of smaller water content Fracture with equal to or more than 1000 pounds/square inch when cast product measures under 1500 °F caused by elements for castable compositions Modulus.
19. elements for castable compositions, when with 2.8 weight % or the cast of smaller water content, poured caused by the elements for castable compositions Crushing strength with equal to or more than 3000 pounds/square inch when note product measures under 230 °F, the elements for castable compositions Comprising at least 50 weight % most thick fire resisting particle size fraction for accounting for dry composition, wherein most thick fire resisting particle size fraction leads to smaller particle size level It is at least that the largest particles diameter, which is crossed, with smallest particles diameter ratioInterval separate.
20. according to the elements for castable compositions described in claim 1,16 or 19, it is straight by particle to contain at least three for wherein said composition The ratio between footpath is at leastThe particle size fraction that separates of interval, and at least three particle size fraction is less than 100 microns by diameter completely Particle form.
21. according to the elements for castable compositions described in claim 1,16 or 19, wherein when the cast product measures under 230 °F Porosity with equal to or less than 6 volume %.
22. elements for castable compositions according to claim 19, wherein the cast product has when being measured under 230 °F 5000 pounds/square inch of crushing strength.
23. elements for castable compositions according to claim 19, should when with 2.8 weight % or the cast of smaller water content Cold pressing with equal to or more than 3000 pounds/square inch when cast product measures under 1500 °F caused by elements for castable compositions Broken intensity.
24. according to the elements for castable compositions described in claim 1,16 or 19, two of which particle size fraction distribution of peaks corresponds to diameter For the particle below 250 nanometers.
25. according to the elements for castable compositions described in claim 1,16 or 19, its micron fraction of Central Asia 100 shows 3 granularities Level.
26. according to the elements for castable compositions described in claim 1,16 or 19, wherein in the distribution of particles of sub- 100 micrometer ranges Introduce interval.
27. according to the elements for castable compositions described in claim 1,16 or 19, also comprising A3000FL, it is with 2.5-3 microns D50 and pass through the specific surface area that BET (Brunauer-Emmett-Teller) method measures be typically 1.3-2 square metres/ Gram ultra-fine, bimodal activity aluminum oxide.
28. according to the elements for castable compositions described in claim 1,16 or 19, also comprising A152SG, it is to be with median particle diameter The ultra-fine alumina of 1.2 microns of unimodal particle size distribution.
29. according to the elements for castable compositions described in claim 1,16 or 19, also comprising RG4000, it is micro- with 0.5-0.8 The d50 of rice unimodal activated alumina.
30. according to the elements for castable compositions described in claim 1,16 or 19, also comprising A3000FL and A152SG.
31. according to the elements for castable compositions described in claim 1,16 or 19, also comprising A3000FL and RG4000.
32. according to the elements for castable compositions described in claim 1,16 or 19, also comprising A152SG and RG4000.
33. according to the elements for castable compositions described in claim 1,16 or 19, also comprising A3000FL, A152SG and RG4000.
34. elements for castable compositions, when with 2.8 weight % or the cast of smaller water content, poured caused by the elements for castable compositions Note product porosity with equal to or less than 15 volume % when being measured under 230 °F, the wherein elements for castable compositions contain to Few 4 particle size fractions, wherein 3 neighbouring particle size fractions are at least by the ratio between particle diameterInterval separate, and this 3 Individual neighbouring particle size fraction has following residuals weight percentage, and the residuals weight percentage is on each close to larger particles Scale particle size level and by successively decrease particle size order be smaller value, higher value and smaller value.
35. elements for castable compositions, when with 2.8 weight % or the cast of smaller water content, poured caused by the elements for castable compositions Note product porosity with equal to or less than 15 volume % when being measured under 230 °F, the wherein elements for castable compositions contain to Few 4 particle size fractions, wherein 3 neighbouring particle size fractions are at least by the ratio between particle diameterInterval separate, and this 3 Individual neighbouring particle size fraction has following residuals weight percentage, and the residuals weight percentage is on each close to larger particles Scale particle size level and by successively decrease particle size order be higher value, smaller value and higher value.
36. elements for castable compositions, when with 2.8 weight % or the cast of smaller water content, poured caused by the elements for castable compositions Note product porosity with equal to or less than 15 volume % when being measured under 230 °F, the wherein elements for castable compositions contain to Few 4 are at least by the ratio between particle diameterThe particle size fraction that separates of interval, and at least four particle size fraction each In residuals weight percentage be at least 40%.
37. the cast product produced as the elements for castable compositions any one of claim 1-36.
38. the method for producing cast product, comprising：(a) mould with cavity is provided, the cavity corresponds to the chi of product Very little and shape, (b) fill the cavity with the elements for castable compositions any one of claim 1-36, and (c) is optionally by institute State elements for castable compositions to be compacted and/or vibrated, (d) solidifies the elements for castable compositions to form cast product, and (e) by mould Tool separates with cast product.
39. the method for producing cast product, comprising：(a) mould with cavity is provided, the cavity corresponds to the chi of product Very little and shape, (b) fill cavity with the elements for castable compositions any one of claim 1-36, and (c) is to described pourable Composition is compressed processing, and (d) solidifies the elements for castable compositions to form cast product, and (e) by mould and pours into a mould product Separation.
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